CA1238155A - Conductive fiber mat - Google Patents

Conductive fiber mat

Info

Publication number
CA1238155A
CA1238155A CA000462739A CA462739A CA1238155A CA 1238155 A CA1238155 A CA 1238155A CA 000462739 A CA000462739 A CA 000462739A CA 462739 A CA462739 A CA 462739A CA 1238155 A CA1238155 A CA 1238155A
Authority
CA
Canada
Prior art keywords
fibers
web
binder
composite
coated carbon
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000462739A
Other languages
French (fr)
Inventor
Robert D. Giglia
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Wyeth Holdings LLC
Original Assignee
American Cyanamid Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by American Cyanamid Co filed Critical American Cyanamid Co
Application granted granted Critical
Publication of CA1238155A publication Critical patent/CA1238155A/en
Expired legal-status Critical Current

Links

Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00Electrodes
    • H01M4/02Electrodes composed of, or comprising, active material
    • H01M4/64Carriers or collectors
    • H01M4/70Carriers or collectors characterised by shape or form
    • H01M4/80Porous plates, e.g. sintered carriers
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/36Inorganic fibres or flakes
    • D21H13/46Non-siliceous fibres, e.g. from metal oxides
    • D21H13/50Carbon fibres
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H5/00Special paper or cardboard not otherwise provided for
    • D21H5/12Special paper or cardboard not otherwise provided for characterised by the use of special fibrous materials
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00Electrodes
    • H01M4/02Electrodes composed of, or comprising, active material
    • H01M4/24Electrodes for alkaline accumulators
    • H01M4/26Processes of manufacture
    • H01M4/28Precipitating active material on the carrier
    • H01M4/29Precipitating active material on the carrier by electrochemical methods
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00Electrodes
    • H01M4/02Electrodes composed of, or comprising, active material
    • H01M4/64Carriers or collectors
    • H01M4/70Carriers or collectors characterised by shape or form
    • H01M4/72Grids
    • H01M4/74Meshes or woven material; Expanded metal
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10Energy storage using batteries

Landscapes

  • Chemical & Material Sciences (AREA)
  • General Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Engineering & Computer Science (AREA)
  • Inorganic Chemistry (AREA)
  • Cell Electrode Carriers And Collectors (AREA)
  • Paper (AREA)
  • Inert Electrodes (AREA)
  • Conductive Materials (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)
  • Battery Electrode And Active Subsutance (AREA)

Abstract

TITLE OF THE INVENTION
CONDUCTIVE FIBER MAT

ABSTRACT OF THE DISCLOSURE

A process for the production of a conductive fiber mat comprising forming a slurry of metal coated carbon fibers and binder fibers, laying down a mat from said slurry and drying the resultant mat is disclosed. The dried mat may then be sistered and/or formed into composites by encapsul-ating in a resin.

Description

~3~S5 CONDUCTIVE FIBER MAT

BACKGROUND OF THE INVENTION

Conductive fiber mats produced from woven metal coated carbon fibers are known in the art. These mats, however, have not proven to be commercially attractive because their method of manufacture is relatively expensive and the conductivity of the mats tends to be an isotropic.
Non-woven conductive fiber mats produced from metal coated carbon fibers are also known. These mats are produced utilizing resinous materials as binders for the fibers. The use of such resinous binders has proven unset-is factory, however, because the metal coated carbon fibers tend to agglomerate during the formation of the mat. The result is a product which is not of uniform conductivity and is therefore not useful for many service applications.
Therefore, if a conductive fiber mat could be formed which overcomes the above deficiencies of prior mats, an advance in the art would be achieved.
SUMMARY OF THE INVENTION
Uniformly conductive mats prepared from metal coated fibers have been produced by employing a fibrillated fiber as the binder material. The use of the fibrillated fiber binder improves the dispersion of the metal coated carbon fibers throughout the mat thereby resulting in a more uniform product. The uniformity is further improved by controlling the length of the metal coated carbon fibers.
The instant invention provides a low cost, lightweight, 'I, ', highly conductive mat suitable for lamination into compost-lo structures requiring electrical conductivity.
DESCRIPTION OF THE INVENTION
INCLUDING PREFERRED EMBODIMENTS
_ - The present invention relates to a process for the production of a conductive fiber mat comprising forming a slurry of a mixture of metal coated carbon fibers and fibrillated binder fibers, the amount of binder fibers ranging from about 1-15%, by weight, based on the total weight of binder fibers and carbon fibers, laying the mixture of fibers down from said slurry as a random non-woven web and drying the resultant web.
The metal coated carbon fibers useful in the pro-cuss of the present invention to produce the conductive mats are well known in the art as are methods for their product lion. For example, U.S. Patent Nos. 3,622,283 and 4,132,828 are exemplary of procedures for their production. The metal used to coat the carbon fibers can comprise any known metal useful therefore including, but not limited to, nickel, silver, zinc, copper, lead, arsenic, cadmium, tin cobalt, gold, indium, iridium, iron, palladium, platinum, teller I'm, tungsten or mixtures thereof.
The carbon fibers can be prepared from such carbon fiber precursors as coal tar pitch, petroleum pitch, coal tar, petroleum derived thermal tar, ethylene tars, high-boiling coal tar distillates, ethylene tar distillates, gas oils or polynuclear aromatics. Also useful as precursors are polymers such as acrylonitrile homopolymers and co-polymers, polyvinyl alcohol, and natural and regenerated cellulose. Methods for preparing carbon fibers useful herein are disclosed in U.S. Patent Nos. 4,069,297 and 4,285,831.

The carbon fibers can be of any length although for practicality they should be less than about 15 mm in length.
Preferably, and in order to achieve even further uniformity in the mats, the length of the majority of the metal coated carbon fibers should not exceed about 3mm. Yost preferably, the fiber length of the metal coated carbon fibers should not exceed about 2mm. ,' The binder fiber, used in amounts ranging from about 1% to about 15%, by weight, based on the total weight of fibers present in the fiber mixture, can comprise any fibrous material capable of being fibrillated. For example, cellulosic fibers, acrylic fibers, polyester fibers and the like may be used. These fibers may be fibrillated in lo accordance with art recognized procedures such as for example, high speed shearing. The binder may also b of any practical length, however it is preferred that they not exceed 15 mm.
The preferred binder fibers are those capable of fibrillation which are decomposed upon sistering i.e. will substantially disintegrate upon heating to temperatures ranging from about 600C to about 800C. Thus, the preferred binder fibers are acrylic fibers produced from homopolymers and copolymers of acrylonitrile.
The mats are produced by laying down the mixture of fibers from a slurry thereof. The slurry may be in a liquid such as water or in a gas such as air. That is to say, the web may be laid-down by using a wet-laying process (paper-making process) or a dry-layer process, i.e. from an air suspension onto a pheromones belt with the aid of a vacuum applied from below the belt as is known in the art see U.S.
Patent No. 4,353~686.
Once prepared, the mats are readily sistered, as mentioned above, if still higher conductivity is desired.
Sistering can be achieved at temperatures ranging from 700C
to 1100C, under compression and in humidified hydrogen.
Sistering decomposes the binder fiber leaving contamina-tion-free surfaces which further facilitate the sistering operation.
The mats, before or after sistering, may be formed into composites by encapsulation into a resinous material such as epoxy resins polyester resins and the like. This is accomplished by coating, dipping, immersing, etc. the mat in the resinous material and then curing under heat and/or pressure.
The mats produced by the process of the present invention have a wide variety of uses. They are useful as EM shielding composites, heater blankets, pads and elect troves for electro-chemical devices, i.e. batteries, elect ironic enclosures, heater plates and the like.
The following examples are set forth for purposes of illustration only and are not to be construed as limit-lions on the present invention except as set forth in the appended claims. All parts and percentages are by weight unless otherwise specified.

I

~23~3~L55 To a suitable shearing apparatus is added 1.0 part of commercially available nickel plated carbon fibers in 200 ml. of-deionized water. The fibers are sheared for 30 minutes until a majority of the fibers are no longer than about 3mm. One part of fibrillated acrylic fibers is then added along with flocculating agent and a surface-active agent. An additional 3.9 parts of the nickel plated carbon fibers are added and the complete system is sheared for 2-3 minutes.
The resultant fiber slurry is then drawn down into a sheet using a conventional hand sheet-making machine. The resultant sheet is rolled between blotter paper to remove excess water before drum drying.
The dry sheet is cut to size and assembled into a sandwich with a sheet of metal screen between two pieces of dry sheet. The laminate is placed between shims and carbon steel bars and placed in a furnace with humidified hydrogen flowing at approximately 400 cc/min. for 60 minutes. The furnace temperature is 800C. After 2 hours, the furnace is cooled to 200C and nitrogen gas is admitted until the furnace is at room temperature. The sample is removed and found to be sistered at the crossover points of the coated fibers. No trace or residue can be found of the acrylic fibers by microscopic examination.

The procedure of Example 1 is again followed except that only 7% of the fibrillated acrylic fibers is used. The sheet is recovered from the sheet-making machine, dried and cut into 12" x 12" x .010" samples. The area density is measured as 1.86 oozed, the volume density us .225 g/cm3 and the surface resistivity as Okay.. A mold lo made from two glass plates 10" x 12" and a 3/32" plastic mold head. The glass plates are sprayed with a release agent and a common-Shelley available epoxy resin-hardener system is charged to the mold after degas sing. The cut fibrous sheet is lowered into the liquid epoxy resin and the entire mold is cured at ~38~55 50C for hours and then room temperature for 6 hours. The glass plates are removed and the resultant sheet is cut into a 9" x 9" sample. The sheet weight 120.5 grams, has a density of 68 oozed, a volume density of 1.16 g./cm3 and a volume resistivity of 0.0823 ohm/cm. This value is estimated to provide better than 40 dub attenuation in a radio frequency shielding application, a value indicated in the literature as acceptable for most equipment applications.

The procedure of Example 2 is again followed except that fibrillated cellulosic fibers are used to replace the acrylic fibers. Similar results are achieved.

Replacement of the nickel coated carbon fibers of Example 2 with silver coated graphite fibers achieves sub-staunchly equivalent results.

The epoxy resin of Example 2 is replaced by a polyamide resin. The resultant sheet is substantially equivalent to the sheet of Example 2.

Air-laying the fiber mixture of Example 1 in the absence of-flocculant and surface-active agent results in an excellent non woven mat of equivalent properties.

The sample sheet of Example 1 is impregnated with active materials and converted to the hydroxides required for a nickel-cadmium battery application using the process of R. L. Beau champ, Electrochemical Society Meeting, En-tended Abstracts #65, October 1970, p. 161 and later refined by D. F. Picket, "Fabrication and Investigation of Nickel-Alkaline Cells, "Part I, AFAPL-TR-75-34, 1974 at the Air Force Astro-Propulsion Laboratory. The sheet is placed between two nickel electrodes in a holding frame so that the sheet does not contact either electrode. The frame is submerged in a 50/50 water-ethanol solution containing 1.8 molar nickel nitrate and 0.2 molar cobalt nitrate. The sheet ... .

~3~L55 is cathodized at 0.5 amperes/in2 for a period of about 2 hours. Next the sheet is removed from the solution, washed in deionized water and placed in a 35 weight-% potassium hydroxide solution. Cathodization of the sheet is performed at 0.5 amperes/in2 for 20 minutes and the polarity is reversed and the sheet is anodized using the same current-time schedule. This process of cathodization and anodize-lion is repeated several times after which the sheet is washed in deionized water, dried and cut up into plates. The resultant nickel battery plates are assembled into nickel-cadmium cells using a matching number of commercial cadmium plates and nylon woven separator. The result is an excellent battery.

1, 1,

Claims (20)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A process for the production of a conductive fiber mat which comprises a) forming a slurry of a mixture of metal coated carbon fibers and fibrillated binder fibers, the amount of binder fibers ranging from about 1-15%, by weight, based on the total weight of binder fibers and metal coated carbon fibers, b) laying the fibrous mixture down from said slurry as a random non-woven web, and c) drying the resultant web.
2. A process according to Claim 1 wherein the binders fibers are cellulosic fibers.
3. A process according to Claim 1 wherein the binder fibers are acrylic fibers.
4. A process according to Claim 1 wherein the metal coated carbon fibers are nickel coated.
5. A process according to Claim 1 wherein the dried web is sintered.
6. A process according to Claim 1 wherein the dried web is formed into a composite by encapsulation in an encapsulating resin and curing.
7. A process according to Claim 5 wherein the sintered web is formed into a composite by encapsulation in an encapsulating resin and curing.
8. A process according to Claim 1 wherein the majority of the metal coated carbon fibers are less than about 3mm in length.
9. A web comprising a dry sheet of a mixture of metal coated carbon fibers and fibrillated binder fibers, the amount of binder fibers ranging from about 1-15%, by weight, based on the total weight of binder fibers and metal coated carbon fibers.
10. A web according to Claim 9 wherein the binder fibers are cellulosic fibers.
11. A web according to Claim 9 wherein the binder fibers are acrylic fibers.
12. A web according to Claim 9 wherein the coated carbon fi-bers are nickel coated.
13. A web according to Claim 9 wherein the sheet is sintered.
14. A composite comprising the web of Claim 9 encapsulated into a cured encapsulating resin.
15. A composite according to Claim 14 wherein the binder fi-bers are acrylic fibers.
16. A composite according to Claim 14 wherein the binder fi-bers are cellulosic fibers.
17. A composite according to Claim 14 wherein the metal coated carbon fibers are nickel coated.
18. A composite according to Claim 14 wherein the encapsulated web is sintered.
19. The composite of Claim 14 in the form of a battery plate.
20. The composite of Claim 14 in the form of a radio frequency shielding.
CA000462739A 1983-09-12 1984-09-10 Conductive fiber mat Expired CA1238155A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US53136583A 1983-09-12 1983-09-12
US531,365 1983-09-12

Publications (1)

Publication Number Publication Date
CA1238155A true CA1238155A (en) 1988-06-21

Family

ID=24117328

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000462739A Expired CA1238155A (en) 1983-09-12 1984-09-10 Conductive fiber mat

Country Status (5)

Country Link
EP (1) EP0139193B1 (en)
JP (1) JPH07100917B2 (en)
AT (1) ATE28911T1 (en)
CA (1) CA1238155A (en)
DE (1) DE3465356D1 (en)

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS61225398A (en) * 1985-03-28 1986-10-07 愛媛県 Sheet like composition containing coudnctive fiber
JPS61289200A (en) * 1985-06-11 1986-12-19 アイシン精機株式会社 Production of metal fiber sheet
JPS6267808A (en) * 1985-09-20 1987-03-27 松下電器産業株式会社 Polarizing electrode
JPS62191599A (en) * 1986-02-19 1987-08-21 静岡県 Production of inorganic paper
JPH0622133B2 (en) * 1986-05-28 1994-03-23 株式会社明電舎 Positive electrode for metal-halogen batteries
JPH076159B2 (en) * 1986-06-27 1995-01-30 東邦レーヨン株式会社 Conductive mixed paper for EMI shield material
GB0805640D0 (en) * 2008-03-28 2008-04-30 Hexcel Composites Ltd Improved composite materials
US9062417B2 (en) 2013-03-14 2015-06-23 Neenah Paper, Inc. Methods of molding non-woven carbon fiber mats and related molded products
CN115180224B (en) * 2022-07-18 2023-08-08 巩义市泛锐熠辉复合材料有限公司 Automatic impregnation and sheet collecting device and method for sheet fiber mats

Family Cites Families (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1266097A (en) * 1959-08-18 1961-07-07 Kimberly Clark Co Method of manufacturing an electrically conductive paper
NL6601906A (en) * 1965-02-23 1966-08-24
JPS5213214B2 (en) * 1972-10-06 1977-04-13
JPS5190338A (en) * 1975-02-06 1976-08-07
JPS51102106A (en) * 1975-02-28 1976-09-09 Mitsubishi Chem Ind DODENSEIKISHI
US4332853A (en) * 1977-05-09 1982-06-01 International Business Machines Corporation Conductive plastic with metalized glass fibers retained in partial clumps
FR2425937A1 (en) * 1978-05-17 1979-12-14 Arjomari Prioux FIBROUS STRUCTURE CONTAINING METAL FIBERS, ITS PREPARATION PROCESS, AND ITS APPLICATION ESPECIALLY IN THE PAPER INDUSTRY
FR2432220A1 (en) * 1978-07-25 1980-02-22 Michelin & Cie ZINC ELECTRODE
US4352768A (en) * 1978-09-05 1982-10-05 Gte Laboratories Incorporated Fiber reinforced cathode for electrochemical cell
JPS5852302B2 (en) * 1979-01-18 1983-11-21 豊化学工業株式会社 Electrode plate for alkaline storage battery
US4388422A (en) * 1979-04-16 1983-06-14 Dart Industries Inc. Fiber-reinforced composite materials
US4347104A (en) * 1979-05-18 1982-08-31 Minnesota Mining And Manufacturing Company Moisture-insensitive electrically-conductive paper
US4215190A (en) * 1979-06-08 1980-07-29 Ferrando William A Lightweight battery electrode
JPS5699968A (en) * 1980-01-12 1981-08-11 Nippon Muki Kk Separator for battery
JPS57115702A (en) * 1981-01-09 1982-07-19 Mitsubishi Paper Mills Ltd Conductive paper
US4752415A (en) * 1982-03-16 1988-06-21 American Cyanamid Co. Compositions convertible to reinforced conductive components and articles incorporating same

Also Published As

Publication number Publication date
ATE28911T1 (en) 1987-08-15
JPH07100917B2 (en) 1995-11-01
JPS6088198A (en) 1985-05-17
EP0139193A2 (en) 1985-05-02
EP0139193A3 (en) 1985-06-05
DE3465356D1 (en) 1987-09-17
EP0139193B1 (en) 1987-08-12

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